Carton palletizing apparatus



Aug. 1 1, 1.970 ROTH ET AL CARTON PALLETIZING APPARATUS ll Sheets-Sheet 1 Original Filed March 2, 1967 Aug. 11, 1970 ROTH ET AL CARTON PALLET I Z ING APPARATUS 11 sheets-sheet 2 s W2 Z M i Q #5 0 y i W u 2M 2 Original Filed March 2, 1967 Aug. 11, 1970 I 5 ROTH ETAL 3,523,601

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CARTON PALLETIZING APPARATUS Original Filed March 2, 196? ll Sheets-Sheet '7 Aug. 1 1, 1970 Original Filed March 2, 1967 E. E. ROTH ETAL CARTON PALLETIZING APPARATUS lit FEE] 11 Sheets-Sheet 9 zwgw Aug. 11, 1 970 ROTH ETAL CARTON PALLETIZING APPARATUS Original Filed March 2, 1967 ll Sheets-Sheet 1O hm QM Aug. 11,1970 5. ROTH ETAL 3,523,601

CARTON PALLETIZING APPARATUS Original Filed March 2, 1967 11 Sheets-Sheet 11 FIG,2O FIG.2I

United States Patent 3,523,601 CARTON PALLETIZING APPARATUS Ernest E. Roth, Arnold, and Henry E. Tanner, Affton,

Mo., assignors to Alvey, Inc., St. Louis, Mo., a corporation of Missouri Original application Mar. 2, 1967, Ser. No. 620,090, now Patent No. 3,442,400, dated May 6, 1969. Divided and this application Oct. 14, 1968, Ser. No. 786,522

Int. Cl. B65g 47/24, 57/00 11.8. Cl. 198-33 11 Claims ABSTRACT OF THE DISCLOSURE A carton palletizing apparatus of substantially floor level layout in which cartons are fed to make-up compact patterns of cartons on a continuously operating powered roller table and then transferred as patterns to a stacking device. The powered roller table includes means for turning selected cartons, means for arranging the cartons in side-by-side relation, means for stopping the advance of the cartons over the rollers so that succeeding cartons accumulate, and means for compacting the accumulated cartons transversely of the direction of advance so as to complete the pattern. The stacking device sequentially elevates each pattern of cartons formed on the table and retains the same in elevated position such that a stack of patterns is built up from the bottom until a desired number of layers is collected. The stacking device then receives a pallet and raises the pallet under the stack where the stack is transferred onto the pallet and the thus loaded pallet is lowered and conveyed away or removed by suitable means, as by a fork-lift truck. The apparatus is provided with a system of controls that can form predetermined patterns, arrange for interlocked layers in a stack, and generally operate substantially automatically so long as the cartons are continuously supplied.

This application is a division of our co-pending application, Ser. No. 620,090, filed Mar. 2, 1967, now Patent No. 3,442,240 issued May 6, 1969.

Palletizing apparatus heretofore available to the indus try has generally involved large, high rise and expensive mechanism that is complicated to manufacture, is cumbersome to ship to the place of use and set up properly, and is large and high so that carton feeding conveyor systers are rendered expensive to set up. Most of the prior apparatus has been designed to stack layers of cartons from the top, thus demanding height in the apparatus to accommodate the top stacking mode of operation.

The important objects of the present invention are to overcome the problems of construction, the size of apparatus, the high level conveyance and handling of cartons, and the complications and expenses normally associated with prior apparatus.

Other important objects of the present invention are to provide a low level, table height apparatus that utilizes relatively standard components, improved stacking means for layering patterns of cartons from the bottom to accelerate the palletizing operation, and reduction in the construction costs, expense of shipment of the total apparatus by having smaller and less bulky units.

There is disclosed herein certain preferred forms of palletizing apparatus which illustrate the principles of this invention, said forms being disclosed in more detail in the following description when considered in view of the accompanying drawings, wherein:

FIG. 1 is a plan view of carton palletizing apparatus illustrating a preferred form and organization of components;

3,523,601 Patented Aug. 11, 1970 FIG. 2 is a longitudinal and partly sectional view of the apparatus as seen along line 2-2 in FIG. 1;

FIG. 3 is a perspective view of the table frame utilized in the apparatus of FIG. 1;

FIG. 4 is a fragmentary perspective view of a component in the apparatus of FIG. 1, the showing being on an enlarged scale taken from below the table frame;

FIG. 5 is an enlarged fragmentary view of the stop means in the conveyor system of the apparatus;

FIG. 6 is an enlarged transverse sectional view taken at line 66 in FIG. 1;

FIG. 7 is an enlarged fragmentary sectional view taken at line 7-7 in FIG. 6;

FIG. 8 is a greatly enlarged and fragmentary sectional view of a stacking device in the apparatus of FIG. 1, the view being taken along line 88 thereof;

FIG. 9 is a partly sectional plan view of the stacking device as seen along line 9-9 in FIG. 8;

FIG. 10 is a simplified perspective view of the stacking device shown in FIG. 8;

FIG. 11 is a schematic view of the action of the pattern control guide means associated with the apparatus of FIG. 1;

FIG. 12 is a fragmentary detail view of the stabilizing means for the elevating table shown in FIG. 8;

FIG. 13 is a typical compacting dam and actuating means to lock and release the darn, the means being incorporated in pairs in the stacking device of FIG. 8;

FIG. 14 is a fragmentary sectional view of the coordinated carton stop means employed with the elevating table in the stacking device of FIG. 1;

FIG. 15 is also a fragmentary sectional view of the braking means employed to stop the rollers in the elevating table of the stacking device of FIG. 1;

FIGS. 16A to 16F are schematic elevational views of the sequential steps in the operation of the carton stacking device of FIG. 1;

FIG. 17 is a greatly simplified circuit diagram by which the several functions and sequential steps of the palletizing apparatus of FIG. 1 may be coordinated and controlled;

FIG. 18 is a schematic plan view of the apparatus embodying the control system of FIG. 17;

FIG. 19 is a plan view of a modified palletizing apparatus embodying the components and control features illustrated in the foregoing view, but enlarged to include pallet loading and loaded pallet discharge;

FIG. 20 is a plan view of another modification for forming carton patterns; and

FIG. 21 is still another plan view of a modified palletizing apparatus for forming carton patterns.

Turning now to FIGS. 1, 2 and 3, the palletizing apparatus A is organized on a low level conveying table structure (FIG. 3) which includes longitudinal side members 23, 24, 25, 26 and 27, and is supported by pairs of legs 28, 29 and 30. A series of load supporting rollers are suitably supported at the opposite ends in the side members 21 and 22, so as to form a load-supporting bed, the rollers being arranged in groups, as follows: The group of rollers 31 comprise a carton receiving section on the table; the next group of rollers 32 comprise a car ton pattern collecting section on the table; and the next group of rollers 33 comprise a carton compacting and loading section on the table. Between the groups of rollers 31 and 32 there is positioned a large diameter carton turning roll 34 which cooperates with adjustably fixed turning abutments 35 located at the opposite ends of the turning roll 34. Each abutment 35 is faced with a friction or arresting pad 36 which retards or arrests the sliding action of a corner or other part of a carton to the extent that the carton swings or pivots into a position rotated about 90 degrees from its alignment when issuing from between a pair of pattern control guides or deflectors 37. The pivoting carton passes over the turning roll 34 and is quickly stabilized in its correct turned attitude. The turning roll 34 and the abutments 35 in combination form turning means, whereas the control guides 37 form arranging means.

Between the group of rollers 32 and 33 there is a stop roll or means 38 which may on command rise above the upper load supporting surface of rollers 32 to stop passage of cartons. At the end of the group of rollers 33 there is another stop roller 39 which also on command rises above the top surface of rollers 33 to stop the passage of cartons. The supply of cartons is obtained from a conventional roller conveyor the end of which is seen at 40. Between this conveyor 40 and the rollers 31 there is disposed a carton speed-up belt conveyor 41 whereby cartons arriving in end to end abutment from conveyor 40 can be separated to create a desired spacing so that each carton can proceed to move between the control guides 37. The group of rollers 31 also are operated to increase the carton spacing so that little opportunity is aiforded for carton pile up, unless an obstruction develops.

As an example of the belt and roller drive means there is seen in FIG. 2 a drive motor 42 mounted on the legs 43 of the belt conveyor frame. The motor 42 is connected by sprocket chain 44 to the end of the belt drive roll 45. The belt 41 is trained over a roll 46 and returns through a slack take-up device 47. The roll 46 drives a gear 48 which meshes with a direction reversing gear 49 (FIG. 1) of a speed gear 50. The speed gear 50 drives a belt 51 passing in driving engagement under the group of rollers 31 and runs through a slack take-up device 52. The turning roller 34 has a separate drive by sprocket chain 53 from motor 54. All of the rollers 32 and 33 are driven from a common motor 55 and sprocket chain 55a, the drive belt 56 passing against the under side of these rollers and through a slack take-up device 57. In one preferred apparatus A, and to illustrate the operation thereof, the cartons were fed by conveyor 40 at about 50 f.p.m. and accelerated by belt 41 to about 137 f.p.m. to effect a spacing thereof. Each carton on reaching the rollers 31 was speeded up to about 148 f.p.m. to increase the spacing due to the action of the pattern control guides 37 in fanning back and forth widthwise of the rollers 31, as will be explained presently. The turning roller 34 was driven at a speed to move the cartons at about 210 f.p.m. to complete carton turning rapidly and stabilize the turned position, after which the rollers 32 and 33 were driven to effect carton movement at about 180 f.p.m. to elfect the collecting and movement of cartons in a pattern. Of course, other linear speeds can be selected, depending upon the character of carton contents and weight, and in this connection the term carton shall be taken to mean any article, case, bag or box which has suflicient shape retention ability to be caused to turn 'by the action of the friction surfaces 36 and roll 34, and be responsive to pushing so as to move into a compact pattern.

Still with reference to FIGS. 1, 2, 4 and 5, it is seen that the groups of powered rollers 31, 32 and 33 assemble and advance patterns of cartons that have been selected for make-up by the control guides 37. In the section of rollers 31 there are adjustable supports 58 for locating the abutments 35 which initiate carton turning. Beyond the abutments 35 there are guide rails 59 and 60 fixed in position over the group of rollers 32 to act to keep the cartons together in some semblance of the desired pattern. Adjacent the ends of rails 59 and 60, there is the stop roller 38 which on command is raised above the top line of rollers 32. Actuation of stop roller 38 is effected by a pair of bellcranks 61 (one being shown in FIGS. 2 and 5) located at the ends of the roller 38. The bellcrank 61 has its arm 62 (FIG. 5) actuated by the rod 63 of a pressure cylinder motor 64. The base end of the motor 64 is pivoted into bracket 65 carried by the frame side member 21. The side not shown is similar to what has just been described. When the roller 38 is down it bridges the last roller 32 and the first roller 33. In a like manner stop roller 39 is actuated by pressure cylinder motor means 64 moving bellcranks 66 (FIG. 1).

The group of rollers 33 support a pattern of cartons generally assembled near the adjustable guide 67 carried by the frame side member 21. Opposite the guide 67 is a compacting ram 68 which moves over the rollers 33 to compact the cartons against the guide 67 and align the pattern for movement out of the compacting section of rollers 33. Thus, the ram 68 and the adjustable guide 67 form compacting means. The ram 68 is connected by a pair of rods 69 (one being seen in FIG. 4) to slides 70 which move on guide rods 71. The guide rods 71 are supported in and between side member 22 and an intermediate member 72 (see FIG. 3). The slides 70 are cross connected by straps 73, and one strap 73 has an arm 74 to which the end of piston rod 75 is connected. The rod 75 is actuated by the cylinder motor 76 supported by bracket 77 from side member 22.

As is seen in FIG. 2, the drive means 51, 53 and 56 for the rollers 31, 34 and 3233 are operatively supported in the frame (FIG. 3) between the side member 21 and intermediate members 78 and 79. A typical support for the belt means 51 is seen in FIG. 6 where the pulley 80 support belt 51, and the pulley shaft 81 is driven by a sprocket wheel 82 and sprocket chain 82 from gear 50 (FIG. 2). In addition to supporting the pulley 80, the member 78 and a spaced parallel angle member 82 (FIG. 6) support a pair of rods 83 on which slides an actuator 84 (FIG. 7) having a pair of fingers 85 engaged in slots 86 in the lower flanges 87 of the pattern control guides 37. As is seen in FIGS. 6 and 7, the control guides 37 have the carton entrance ends pivoted on shafts 88 supported by the frame cross member 27 on an extension base 89. The actuator 84 is connected to a piston-cylinder motor means 90, the piston rod 91 of which is attached to the drive boss 92 on the actuator and the cylinder of which is attached to the intermediate member 78. The motion of actuator 84 is monitored by a group of cams contained in a box 93 and actuated by the shaft 94 driven by sprocket 95 and chain 96. The chain ends are attached to the boss 92, and one loop of the chain runs over the idler sprocket 97 while the other runs over the cam shaft sprocket 95.

Looking now at FIG. 11, and with due regard to the plan view of FIG. 1, there is shown somewhat diagrammatically the operation of the pattern control guides 37 in order to make up a pattern of eight cartons. In order to make up such a pattern of cartons the control guides 37 must be fanned crosswise of the carton supporting rollers 31 in the receiving section of the table to six different settings. For example, the control guides 37 must initially be positioned in the direction represented by the broken line 1 such that the carton C1 passes between the control guides 37 and is picked up by the acceleration roller 34 without engaging or brushing against the frictron surface 36 on the side abutment 35. Thus carton C1 will proceed straight into its pattern position. The control guides 37 are then moved to position 2 as represented by the broken line 2 where carton C2 is directed straight in and passes over the roller 34 to assume its position along side of carton C1. At this point the control guides 37 are fanned in a counterclockwise direction to a position represented by broken line 3-4, where cartons C3 and C4 in succession are directed so that the leading corner thereof brushes against the friction surface 36 on the abutment 35, causing the cartons to start a turning operation which Is stabilized by the acceleration roller 34 such that each of the cartons is turned to the cartons C1 and C2. Immediately following the passage of carton C4 the control guldes 37 are fanned in a clockwise direction to a position represented by broken line 56 where successive cartons C5 and C6 are directed against the friction surface 36 of abutment 35 to effect a 90 turn before passing into the pattern of the cartons previously collected. The control guides 37 are then moved to the position represented by broken line 7 where carton C7 is directed straight through to take its position along side of the turned cartons C5 and C6. This is followed by the guides being positioned as represented by the broken line 8 where the final carton C8 passes into the pattern without being turned. Thus, the guides 37 together with the guide rails 59 and 60 in effect constitute arranging means for positioning selected cartons in side-'by-side relation. The foregoing description relates to the forming of a pattern of eight cartons which is assembled against the stop roller 38 in a loose fashion. At this time the stop roller 38 is retracted into the surface of the rollers 32 and the loose pattern is advanced to the stop roller 39. Once the pattern has cleared the stop roller 38, this roller immediately rises to isolate the next pattern of cartons from the previous pattern of cartons. While a second pattern of cartons is being assembled the first pattern is being compacted by the action of the ram 68 compressing the cartons into abutting adjacency against the guide 67. When this compacting operation has been completed and the ram 68 set on its withdrawal movement, the stop roller 39 is lowered and the compacted pattern of cartons is fed into a stacking device which will be described presently.

During the compacting and feeding operation for the first described pattern of cartons, the second pattern of cartons is being assembled adjacent stop roller 38 and between the side guide rails 59 and 60. In the second pattern the sequence of assembling the cartons is reversed to the first pattern so that when the patterns are stacked there will be an interlocking relation created as is well understood in this art. It is not believed necessary to repeat the sequence of movement of the control guides 37, except to say that in making up the second pattern cartons C9 and C10 are directed into position with the guides in the position represented by broken line 5-6. Cartons C11 and C12 are positioned with the guides 37 in the respective positions represented by broken lines 7 and 8. Cartons C13 and C14 are positioned with the guides 37 in the respective positions of the broken lines 1 and 2, and finally cartons C15 and C16 are positioned when the guides have moved to the position represented by the broken lines 56. So long as the subject pattern of eight cartons is called for the control guides 37 will fan back and forth as above described first for one pattern and then for the interlocking pattern layout.

It can be appreciated that the groups of load supporting rollers 31, 32 and 33 will greatly accelerate the rate of handling cartons, because a number of different operations can be performed simultaneously in front of the stops 38 and 39. That is to say, while a pattern of cartons is being compacted a second pattern of cartons can be collecting, and while the patterns of cartons are being fed into the stacking device in sequence a third pattern can be readied for assembly, all without interference. The disclosure last above described in connection with FIGS. 1 and 11 represents means for feeding patterns of cartons into a stacking device, and in its broadest sense this portion of the palletizing apparatus A can be thought of as a feeder for the stacking device now to be described.

Referring now to FIGS. 1 and 8, it can be seen that the stacking device B is positioned at the end of the carton pattern forming table such that an elevator frame 100 is positioned initially such that its group of carton supporting rollers 101 are in the plane with the carton supporting rollers 33 in the compacting and loading section previously described. The elevator frame 100 is supported by the ram 102 (FIG. 9) of an elevator hoist unit 103. The elevator hoist unit 103 is supported on suitable floor engaging beams 104 which are part of a general frame composed of beams 105 which are supported on the beams 104 as well as on other beams 104a. Thus a rigid frame work is created for the operating components of the stacking device B. The elevator frame is prevented from twisting out of proper alignment by means of a stabilizing device shown in FIG. 12. This device includes a stabilizer projection 106 running between rollers 107 carried in a frame 108the frame 108 is supported between cross members 109 which are, in turn, supported from the beam structure previously described. It can be seen in FIG. 8 that a safety chain 110 is connected between a frame member 10? and the elevator frame 100 so that the elevating ram 102 can not exceed a predetermined elevation. It can seen in FIG. 9 that the ram 102 works in a cylinder 102a, and that the cylinder has an extension 106:: which engages in the stabilizer 106 for purposes of maintaining proper alignment between the cylinder 102a and the elevator frame 100.

The elevator rollers 101 are adapted to be driven at certain times by a drive belt 111 when the elevator frame 100 is in its lowermost position. The drive belt 111 is operatively supported (FIGS. 2, 8 and 9) on end pulleys 112 which are supported in a suitable frame structure 113 mounted from the main beams 105 as can be seen in FIG. 2. The belt 111 is trained over a drive pulley 114 which is driven by a suitable sprocket chain 115 from motor means 116 supported on a leg 28 of the table frame shown in FIG. 3. The motor means 116 is of reversing type so that the belt 111 can at proper times be directionally controlled for turning the rollers 101 in the elevator frame 100 either to bring the pattern of cartons on to the elevator, and to discharge a loaded pallet from the elevator or to reverse the rollers for the purpose of initially bringing in an empty pallet upon which a stack of cartons is to be deposited.

The stacking device B as is shown in FIGS. 8 and 10 includes a pair of carton supporting carriages 117. The carriages are identical but formed for right and left hand assembly, and it will be appreciated that the same reference numerals will be used on similar parts in order to simplify the description. As can be seen best in FIG. 10, each carriage 117 includes a base frame 118 made up of longitudinal and transverse members, and this frame carries wheels 119 which are adapted to run on the inner flanges of the main longitudinal beams 105. Each base frame 118 is provided with a pair of vertical columns 120 which are adapted to support a channel member 121. The channel member 121 must be of sufficient structural ability, along with the columns 120 and the base frame 118, to form a rigid support for a plurality of tines forming a plane which is substantially tangent to the rollers 101. Thus, support rollers 101 on the elevator frame can be brought up very close to the underside of the tines 122 to minimize any vertical difference in the tine surface relative to the roller surfaces. It can be observed in FIG. 8 that the carriages 117 are operated by piston cylinder motor means in which the cylinder 123 is carried in a central longitudinal extending channel 124 and the piston rod 125 is connected to a fixed arm 126 on the carriage. The piston cylinder motor means 123 are operated in unison so that the carriages 117 move in and out relative to the elevator frame 100 at the same time. Since the tines 122 of the carriages 117 are adapted to support the pattern of cartons, and since the tines must be removed from such support each time a new layer of cartons is brought to the stacking device, it is necessary that the tines be withdrawn from the carton supporting position and in order to accomplish this the cartons must be retained so as not to move outwardly with the tines 122. This is accomplished by means of providing a pair of holding dams 127. Each dam 127 is carried .on a pivoting frame 128 having its lower end pivotally supported in a suitable bracket 129 as can be seen in FIGS. 8, 9 and 13. The pivot frames 128 are provided midway of the vertical height with a cross member 130 for the purpose of cooperating with a retractable looking plate 131. When the locking plate 131 engages the cross member 130 the holding dams 127 are vertically positioned with the dams 127 closely adjacent the pattern of cartons supported on the tines 122. The locking plate 131 is pivotally mounted between a pair of plates 132 carried on the central channel 124, and the pivot shaft 133 for the locking plate 131 carries a depending arm 134 to which is connected an actuating spring 135. It can be observed in FIG. 13 that the spring 135, being anchored to the central channel 124, constantly urges the arm 134 in a direction to lift the locking plate 131 upwardly so as to intercept and prevent the cross member 130 in the pivot frame 128 from passing back over the locking plate 131 once it has moved rightwardly to the locking position.

It can be appreciated that the holding dams 127 must be coordinated with the operation of the carriages 117, and this is accomplished in the following manner: As can be seen in FIG. 8, when the carriages 117 are in their retracted or outermost position each thereof is provided with an abutment element 136 which is engaged with a tab 137 on the lower end of the arm 134, thereby holding the locking plate 131 in its retracted position so that the pivot frames 128 can be drawn backwardly by a spring 138 to rest against a stop 139. As the carriages 117 move inwardly toward each other the abutment elements 136 move inwardly thereby freeing the arms 134, under the influence of spring 135, to permit the stop plates 131 to move to locking positions. However, the plates 131 can not move to locking positions until the cross member 130 in the pivot frames 128 has cleared the top edge of the locking plates. Once this clearance has been established the locking plates will snap upwardly and the curved end edges 131a on each thereof will apply a suitable holding engagement so that the pivot frames 128 will remain inwardly in binding contact with the cartons. As the frames 117 return to the outward position of FIG. 8 the dams 127 are not freed from carton engaging positions until the tines 122 are very nearly at the withdrawn position, at which time the abutment elements 136 engage the tabs 137 on the arms 134 of the locking plates 131 to withdraw the locking plates and thus free the pivot frames 128 so that the dams 127 will be removed from the possibility of interfering with the handling of the cartons.

It will be observed in FIG. 14 that the elevated frame 100 is provided with a pair of coordinated stop gates 140 and 141, gate 140 being located at the carton feed side of the stacking device B and the gate 141 being located at the outlet side of the stacking device. Each gate is comprised of a longitudinal channel member mounted by suitable actuating arms 142 and 143 respectively about the pivot axis of the adjacent elevator rollers 101. The

arms 142 and 143 are interconnected by an actuating rod 144, and the rod 144 is powered by a suitable piston cylinder motor means 145. It will be observed that when the gate 140 is in its full line position for stopping cartons the gate 141 is in its retracted position. The reverse coordination of these gates is shown in broken outline.

It has previously been pointed out that the rollers 101 in the elevator frame 100 are driven in the proper direction by the drive belt 111 when the elevator frame 100 has been lowered so that the rollers 101 engage the drive belt. When the elevator frame v100 is raised it is desirable that the rollers 101 be stopped. This is accomplished by means of a brake device which is shown in FIG. 15. The brake device includes a brake beam 146 having brake lining 147 adapted to engage the rollers. The brake beam 146 is maintained in proper attitude for engaging all of the rollers 101 simultaneously by pivot arms 148 carried in the frame 100. The pivot arms 148 are so positioned with respect to the brake beam 146 that a spring 149 can be utilized to lift the brake beam 146 into proper braking position. Removing the brake pressure is accomplished by a retract arm 150 connected to the brake beam at link 151 and having its opposite end 1152 located in a position to engage a fixed striker 153 (FIG. 8) mounted on the cross member 109. It can be appreciated that as the frame 100 descends relative to the mixed striker 153, the retract arm 150 pivots in a direction to draw the brake beam 146 inwardly against the action of the spring 149 so that the rollers 101 are free from braking restraint and can be freely driven by the belt 111.

Turning now to the views of FIGS. 16A to 16F, it can be seen that the components of the stacking device B have a predetermined sequence of operation which will now be described. In FIG. 16A the carriages 117 are withdrawn so that the dams 127 are free to pivot to open positions. This allows the elevator frame to pass upwardly between the dams 127 to the required heighth such that the tines 122 (FIG. 16B) may be inserted under the first layer of cartons. As the tines 122 pass under the cartons the dams 127 move in and retain the cartons in compact relation on the tines 122. This action allows the hoist to descend empty to receive a second layer. Hoisting the second layer (FIG. 16C) brings the cartons up under the tines 122 to the position shown in FIG. 16D. At this time the carriages 117 withdraw but the dams 127 remain in clamped position against the cartons until the tines 122 are fully withdrawn and the top layer is allowed to drop only a short distance onto the second layer of cartons. In FIG. 16E the elevator frame 100 has raised both layers to the proper heighth so the tines 122 may be inserted under the two layers upon reversal of the carriages 117. The carriages again run inwardly to insert the tines 122 under the two layers and close the dams 127 as before. The elevator frame 100 again descends to receive a third layer, and in FIG. 16F the third layer is brought up to a position where the tines 122 may again be withdrawn. The cycle of events as above described is repeated as many times as is needed to build up a multiple layer of cartons. The number of layers is predetermined and under the control of counting means in the box 155 (FIG. 8).

A typical apparatus of the character disclosed in FIGS. 1, 2, 4, 5, 6, 8, 9 and 14 is provided with control means which is disclosed in greatly condensed form in the electrical diagram of FIG. 17 and the schematic layout in FIG. 19. The following will make reference to these views of the drawing, and any others deemed helpful will be referred to. It is, of course, understood that there will be a suitable source of compressed air and a fluid pressure source which need not be shown.

It has been pointed out above that electric motor means 42 (FIG. 2) drives the supply conveyor 40 as 'well as the group of rollers 31 constituting the carton receiving section of the table of load supporting rollers. A separate electric motor means 54 is provided to drive the turning roll 34. Motor means 55 drives the group of rollers 32 in the pattern collecting section of the table and the group of rollers 33 in the compacting and loading section of the table. Fluid pressure motor means 90 (FIG. 6) controls the pattern guides 37, air motor means 7 6 (FIG. 4) operates the compacting ram 68, air motor means 64 and 64' (FIG. 2) operate the respective stops 38 and 39, air motor 145 (FIG. 14) operates the gates and 141, fluid pressure motor means 102 (FIG. 9) operates the hoist 103, and electric motor 116 (FIG. 2) drives the belt 122 for driving the hoist rollers 101.

If it is assumed that the apparatus is just starting up, the operator closes the master switch 200 (FIG. 17) which supplies suitable current (say 110 volt AC.) to the various electric eyes PCl, E1, E2, E3, E4, and E5 stationed about the apparatus in FIG. 1, but represented collectively at 199 in FIG. 17. Concurrently a hydraulic pressure pump (not shown) is started and brings hydraulic fluid up to operating pressure for actuating various motor means in the apparatus, such as motor means 90 driving the pattern control guides 37, the elevator ram 102, and the motor means 123 for actuating the carton supporting carriages 117. Motor means 64, 64', '76 and are operated by compressed air. After a desired time. a time delay unit 201 closes its contact 202 to complete the supply of current to the various means, switches, and

devices provided to handle the operation, either manually or automatically, as may be selected at switch 203. This activation by switch 203 will condition the roller table A and elevator hoist unit B to go into operation, and will start electric motors 54, 55 and 116. No cartons will be fed to the table A until electric motor 42 is started to drive the belt 41 or other means, as well as rollers 31 in the table, by closing switch 204.

It is assumed also that the deflectors 37 are in the position 1 as in FIG. 11 and that the apparatus is programmed for forming layers in the order and sequence shown in FIG. 11. The incoming cartons C1, C2, C3, etc. will pass the electric eye PCl closing and opening its contact PCIA to signal a counting relay in the box 93 to step around and signal the fluid pressure motor 90 through control valves represented (FIG. 17) by solenoids to move the deflectors 37 in the sequential order described in connection with FIG. 11. The cartons are collected against stop roll 38, some being turned by the combined action of the roll 34 and side abutments 35. As the first carton reaches stop roll 38 it breaks the light beam for eye E-1 and that opens contact E-lA. At the proper time in the counting cycle stop roll 38 is retracted by actuation of its air motor 64 through a solenoid control and when the light beam from electric eye E1 is clear the eye contact EIA closes to cause air motor 64 to raise roll 38 to stop the second group of cartons, as shown being assembled in FIG. 11. The first group of cartons runs into stop roll 39 and breaks the light beam from electric eye E2 which closes its contact EZA which signals the compacting ram air motor 76 to move the ram 68 in for compacting the cartons and in this movement it will open limit switch LSA and in the end position actuate a limit switch LSB which will reverse the air motor 76 and signal air motor 64 to lower stop roll 39 so that the compacted cartons may proceed on to the elevator rollers 101. The elevator is provided with a pair of interconnected gates 140-141 subject to movement by the motor means 145. At this stage in the cycle of operation gate 141 is up and gate 140 is retracted.

The feed of the cartons onto the elevator rollers 101 is possible when the frame 100 is in its lowest position, when the gate 140 is retracted, and when the electric eye E3 is not blocked, such as by the presence of a pallet or other cartons. As the group or layer of cartons clears electric eye E2 the motor means 64' for stop roll 39 will raise the same to catch the next following group of cartons. When the cartons move into the elevator unit B and block the electric eye E3 the contact E3A will close and hoist motor means 102 will be signalled by switch means in box 155 to rise. This being the first layer in a load, the carton supporting carriages 117 will move from the out positions by actuation of motor means 123 after the hoist 103 has elevated the cartons to its maximum heighth position so that they are carried above the level of the tines 122. The motion of the hoist 103 is transmitted by cable 157 (FIG. 8) to a series of cams on a rotary shaft (not shown) in the counter box 155. The shaft in the box 155 is rotated oppositely to the tension in cable 157 by a motor (spring tension type) 158 so that as the hoist 103 descends the rotary shaft will follow the movement and actuate suitable microswitches.

When the hoist 103 reaches the top position, a switch in box 155 will signal the motor means 123 to move the carriages 117 inwardly so that the tines 122 slide under the cartons. At the proper in position of tines 122 the limit switches LS4 are actuated to stop the carriages and signal the hoist 103 to lower and receive a second layer of cartons. The raising of the second and following layers will be slightly different due to a cam in the box 155 which will stop the hoist 103 when the top surfaces of the layer of cartons is just below (about A") the tines 122. Upon stopping the hoist 103 at the latter position, a signal will be sent to the motor means 123 to reverse and withdraw the carriages 117. The withdrawal of the carriages will result in actuation of limit switches LS2 to signal the hoist 103 to continue up to its top position where it supports both layers. The hoist reaching the top position will by cable 157 (FIG. 8) signal the carriages 117 to move inwardly so that the tines 122 support the new load.

This cycle keeps up while a counter in box 155 counts off the desired number of layers wanted in the stack. When the count has been satisfied, stop roll 39 will not be allowed to drop again until the stack on the hoist is removed. Thus, when the hoist 103 gets to the bottom on its last trip and when it blocks the electric eye E4, the hoist table having taken on a pallet P, it will be signalled to rise until it stops just under tines 122. At this point, a cam switch in box 155 will stop the hoist and move the carriages 117 out. Actuation of the out limit switches LS2 will indicate that the hoist 103 can lower to its down position, and when it reaches the position the hoist rollers 101 will engage a moving belt 111 driven by motor means 116. Simultaneously, the stop gates -141 will be actuated by air motor means to hold gate 140 (FIG. 14) raised and gate 141 lowered. The rollers 101 are driven to urge the pallet loaded with layers of cartons out of the apparatus onto any suitable take-away conveyor or onto a suitable lift truck or bed of a take-away conveyance. When the loaded pallet has cleared the electric eye E3, a signal will be received by the motor means 145 to lower gate 140 and raise gate 141 so that a repetitious cycle of loading another pallet can take place in accordance with the foregoing description.

In FIG. 19 there is shown a modified apparatus in which means is provided for bringing empty pallets into the stacking unit B and for taking loaded pallets out. Wherever parts and components are shown in this view that are similar to the parts and components seen in FIG. 1 similar reference numerals will be applied. Previously presented description will, therefore, not be repeated in the interest of brevity.

The apparatus of FIG. 19 includes a conveyor frame for supporting load carrying rollers 161 that may be power operated or may be free turning, as desired. To one side of the frame 160 there is a platform 162 upon which are placed the empty pallets P, either by hand or by a fork-lift truck. The platform 162 is connected by slide members 163 to the frame 160 so that each pallet P can be conveniently moved into position as shown by pallet P. Once the desired stack of cartons has been assembled in the stacking unit B, the pallet P is moved into the elevator frame 100 and elevated to receive the carton stack. The loaded pallet is lowered to the level of the frame 160 and is moved out to the position of loaded pallet P" where it may be removed by a fork-lift truck.

The apparatus of FIG. 19 is shown in connection with the formation of a pattern of cartons different from the pattern formed by the apparatus of FIGS. 1 and 11. This is intended to illustrate the variations of carton pattern control that is available, although the control means described in FIG. 17 is related to the apparatus of FIG. 1.

The apparatus of FIG. 20 illustrates a modified form of apparatus in which a different carton pattern may be made up. Similar parts and components in this view will be denoted by reference numerals used in FIG. 1. The principal difference resides in the formation of layers of 14 cartons instead of 8 cartons.

The apparatus of FIG. 21 illustrates a further modification in which parts and components similar to those in FIG. 1 will be denoted by similar reference numerals. Principally the modified apparatus is preprogrammed to make up layers of nine (9) cartons and in effecting this result, the carton turning roll is divided into two sections 164 and 165 with a bearing 166 disposed therebetween. Section 164 is provided with a drive sprocket 167 and section 165 has a drive sprocket 168 whereby separate motor means, like motor means 54 in FIG. 2, may be provided for rotating either roll section or rotating the sections at different speeds or in reverse directions so that the cartons directed by guides 37 over the adjacent ends may be turned from an end-on position as carton C17 to a cross-wise position as carton C18.

In the various forms of apparatus illustrated herein, the pattern control is predetermined to alternate the carton patterns so that the final stack will be interlocked. However, it is contemplated that the patterns may be made up without reversing so that there will be no interlocking layers.

It should now be understood in what manner the apparatus is intended to function to produce the advantages enumerated above. Having described certain forms of apparatus and a preferred form, it is intended to include variations within the spirit and scope of the appended claims.

What isclaimed is:

1. In carton palletizing apparatus, a carton conveying table having a carton reception end and a carton discharge end, a plurality of rollers in said conveying table to support and propel cartons between said ends, means to arrest cartons at a position between said ends to accumulate a pattern thereof, and roller means disposed in said plurality of rollers and in advance of said arrest means to selectively turn cartons to fit into the pattern to be accumulated, said roller means being driven independently of said plurality of rollers.

2. The apparatus set forth in claim 1 wherein said roller means consists in a pair of axially aligned rollers, and separate means to drive each roller thereof at differential surface speeds to turn cartons therebetween.

3. An apparatus for arranging loads in a predetermined pattern, said apparatus comprising a load supporting bed having a load receiving end and a load discharge end, the bed being adapted to advance loads introduced upon it from its lead receiving to its load discharge end, guide means for directing loads toward selected segments of the bed, a powered turning roller in the bed and having a surface velocity greater than the velocity at which loads are propelled along that portion of the bed which precedes it, and arresting means for arresting movement of a portion of selected loads as the turning roller accelerates other portions of such selected loads, whereby the selected loads will be turned upon the bed.

4. An apparatus according to claim 3 wherein the arresting means includes an abutment which is engaged by a portion of each selected load, thereby arresting movement of that portion of the load; and wherein the turning roller is located adjacent to the abutment.

5. An apparatus according to claim 4 wherein the bed comprises a plurality of rollers located on each side of the turning roller; and wherein drive means rotate the rollers at a surface velocity less than the surface velocity of the turning roller.

6. An apparatus according to claim 5 wherein the surface velocity of the rollers preceding the turning roller is less than the surface velocity of the rollers beyond the turning roller.

7. An apparatus according to claim 3 and further characterized by first stop means for stopping and accumulating loads on the bed beyond the turning roller, and compacting means for moving the loads transversely of the bed into a compact pattern.

8. An apparatus according to claim 7 and further characterized by second stop means located beyond the first stop means for stopping the pattern of loads accumulated at the first stop means; and wherein the compacting means operates on the pattern of loads halted at the second stop means.

9. An ap aratus according to claim 3 wherein the guide means comprises a pair of spaced deflecting arms located above the bed and pivoted for angular movement relative to the bed so that the angle of the arms relative to the bed can be altered, the loads being introduced onto the bed between the arms, whereby the loads may be directed toward selected segments of the bed.

10. An apparatus according to claim 3 wherein the arresting means comprises another roller; mounted coaxial with respect to the turning roller; and wherein the other roller rotates at a velocity less than that of the turning roller.

11. An apparatus for converting loads initially in a single file into a predetermined pattern in which some of the loads are located in side-by-side relation; said apparatus comprising a load supporting bed adapted to accept the single file of loads and advance the loads along it, turning means for turning selected loads relative to the direction of advance, arranging means for ositioning selected loads in side-by-side relation on the bed relative to the direction of advance, stop means located after the arranging means for creating a barrier to the movement of loads along the bed so that succeeding loads accumulate behind the stop means and are compacted in the direction of movement, and compacting means located after the arranging means for compacting the accumulated loads transversely of the direction of advance, whereby the loads are arranged in a predetermined compacted pattern.

References Cited FOREIGN PATENTS 7/1929 Germany.

EDWARD A. SROKA, Primary Examiner 

